Foamed polymer separator for cabling

Abstract

A cable separator comprising a preshaped article having a longitudinal length, wherein said preshaped article is substantially entirely formed of a foamed polymer material having a glass transition temperature greater than 160° C. and being halogen-free is provided. A data communications cable comprising a plurality of conductors and the cable separator of the present invention, wherein said cable separator separates the plurality of conductors is provided. A method of manufacturing a cable comprising the separator of the invention is also provided.

What is claimed is: 
     
       1. A cable separator, comprising:
 a preshaped body having a longitudinal length, 
 wherein said preshaped body is substantially entirely formed of a foamed thermoplastic polymer selected from the group consisting of polyphenylenesulfide, poly(aryletherketone), poly(etheretherketone), and blends thereof; and 
 wherein the preshaped body is halogen-free. 
 
     
     
       2. The cable separator according to  claim 1 , wherein said foamed thermoplastic polymer has a foam rate of between 30% and 80%. 
     
     
       3. The cable separator according to  claim 1 , wherein said preshaped body includes one or more projections extending in an outward direction. 
     
     
       4. The cable separator according to  claim 3 , wherein, said preshaped body is a crossweb. 
     
     
       5. The cable separator according to  claim 1 , wherein said preshaped body is a substantially flat member. 
     
     
       6. A data communication cable, comprising:
 a plurality of conductors; and 
 a separator, including:
 a preshaped body having a longitudinal length, 
 wherein said preshaped body is substantially entirely formed of a foamed thermoplastic polymer selected from the group consisting of polyphenylenesulfide, poly(aryletherketone), poly(etheretherketone), and blends thereof; and 
 wherein the preshaped body is halogen-free, and 
 
 wherein said separator separates said plurality of conductors. 
 
     
     
       7. The data communication cable according to  claim 6 , wherein said foamed thermoplastic polymer has a foam rate of between 30% and 80%. 
     
     
       8. The data communication cable according to  claim 6 , wherein said preshaped body includes one or more projections extending in an outward direction. 
     
     
       9. The data communication cable according to  claim 8 , wherein said preshaped body is a crossweb. 
     
     
       10. The data communication cable according to  claim 6 , wherein said preshaped body is a substantially flat member. 
     
     
       11. The data communication cable according to  claim 6 , wherein said plurality of conductors comprises a plurality of twisted conductor pairs. 
     
     
       12. The data communication cable of  claim 6 , further comprising a protective jacket surrounding said plurality of conductors. 
     
     
       13. A method of manufacturing a cable, comprising the steps of:
 providing a foamed thermoplastic polymer selected from the group consisting of polyphenylenesulfide, poly(aryletherketone), poly(etheretherketone), and blends thereof; 
 extruding said foamed thermoplastic polymer to form a separator having a predetermined shape, the separator being halogen-free; 
 providing a plurality of conductors; 
 positioning said separator between said plurality of conductors after forming said separator having said predetermined shape and without further manipulation of said separator; and 
 extruding an outer jacket that surrounds said separator and said plurality of conductors. 
 
     
     
       14. The method of  claim 13 , wherein said predetermined shape is a crossweb. 
     
     
       15. The method of  claim 13 , wherein said predetermined shape is a substantially flat member.